Conveyor belt management system

ABSTRACT

In addition to the amount of wear of a rubber comprising at least an upper cover rubber of a conveyor belt installed at a use site, data of at least one input item from six input items consisting of an impact force acting on the conveyor belt, a tensile force, an indicator indicating a state of a core, an indicator indicating a state of an endless portion, an indicator indicating a state of a belt conveyor device, and an indicator indicating a use environment of the conveyor belt is input into a server via an input unit, and a calculation unit calculates a remaining service life of the conveyor belt based on the data input and, stored in a storage unit, a belt specification database and a tolerance range database in which a tolerance range for each of the input items is input in advance per belt specification.

TECHNICAL FIELD

The present invention relates to a conveyor belt management system andparticularly relates to a conveyor belt management system capable ofdetermining a suitable replacement period of the conveyor belt andlowering the running costs of the conveyor belt.

BACKGROUND ART

Various conveyed objects, including mineral resources such as iron oreand limestone, are conveyed by a conveyor belt. An upper cover rubber ofa conveyor belt is worn over time by conveyed objects being fed onto theupper cover rubber. The conveyed objects fed onto the upper cover rubberimpact against the upper cover rubber, and conveyed objects that aresharp can cause cuts in the surface of the upper cover rubber. The coreof the conveyor belt may be cut due to flexural fatigue or abnormaltensile forces. In addition to the above, damage to the conveyor beltmay be caused by many factors, and if the damage is great, the conveyorbelt becomes unusable.

If a conveyor belt becomes unusable, the belt line is stopped, and theconveying of the conveyed objects is significantly affected. Also, ifthe replacement period of a conveyor belt is unknown, then morereplacement conveyor belts than necessary must be kept in inventory andinventory management becomes necessary. As a result, running costs aregreatly increased. Furthermore, if the type of conveyed objects conveyedby the conveyor belt changes, the replacement conveyor belts ininventory may not be used. If the time at which the conveyor beltbecomes unusable (replacement period) is known in advance, the stoppageperiod of the belt line can be kept to a minimum, and there is no needto have excessive conveyor belts in the inventory.

In the related art, a management system for determining the replacementperiod of a conveyor belt is proposed (for example, see Patent Document1). In this management system, only the amount of wear of the conveyorbelt is determined and a remaining service life is calculated.

However, there are various other factors such as those described above,not only wear, that actually render the conveyor belt unusable. Thus,there is room for improvement in determining a more suitable replacementperiod for the conveyor belt.

CITATION LIST Patent Literature

Patent Document 1: WO 2013/179903 A

SUMMARY OF INVENTION Technical Problem

An object of the present invention is to provide a conveyor beltmanagement system capable of determining a suitable replacement periodof the conveyor belt and lowering the running costs of the conveyorbelt.

Solution to Problem

To achieve the object described above, a conveyor belt management systemaccording to an embodiment of the present invention comprises:

an input unit with an amount of wear of a rubber comprising at least anupper cover rubber of a conveyor belt installed at a use site as aninput item;

an input unit with at least one input item from six input itemsconsisting of an impact force acting on the conveyor belt, a tensileforce, an indicator indicating a state of a core, an indicatorindicating a state of an endless portion, an indicator indicating astate of a belt conveyor device on which the conveyor belt is installed,and an indicator indicating a use environment of the conveyor belt as aninput item; and

a server into which data of each of the input items are input;

the server comprising a calculation unit and a storage unit,

the storage unit being configured to store a belt specification databasein which specifications of the conveyor belt are input in advance and atolerance range database in which a tolerance range for each of theinput items input into the server per each of the specifications of theconveyor belt is input in advance, and

the calculation unit being configured to calculate a remaining servicelife of the conveyor belt based on the data of the input items inputinto the server, the specifications of the conveyor belt input into thebelt specification database, and the tolerance range input into thetolerance range database.

Advantageous Effects of Invention

According to an embodiment of the present invention, as a basis forcalculating the remaining service life of the conveyor belt, in additionto the amount of wear of the upper cover rubber, at least one input itemfrom six input items consisting of an impact force acting on theconveyor belt, a tensile force, an indicator indicating a state of acore, an indicator indicating a state of an endless portion, anindicator indicating a state of a belt conveyor device on which theconveyor belt is installed, and an indicator indicating a useenvironment of the conveyor belt are used. Accordingly, the remainingservice life that is more accurate to the conditions of the use site ofthe conveyor belt than the related art can be calculated. This makes iteasier to determine a suitable replacement period for the conveyor belt,which is advantageous in reducing the running costs of the conveyorbelt.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an explanatory diagram illustrating an overview of a conveyorbelt management system according to an embodiment of the presentinvention.

FIG. 2 is an explanatory diagram illustrating a belt specificationdatabase.

FIG. 3 is an explanatory diagram illustrating a tolerance rangedatabase.

FIG. 4 is an explanatory diagram illustrating a use condition database.

FIG. 5 is an explanatory diagram illustrating an inventory database.

FIG. 6 is an explanatory diagram simply illustrating a belt conveyordevice mounted with a conveyor belt in a side view.

FIG. 7 is a cross-sectional view taken along A-A of FIG. 6.

FIG. 8 is an explanatory diagram illustrating the structure of anendless portion of the conveyor belt of FIG. 6 in a plan view.

DESCRIPTION OF EMBODIMENTS

A conveyor belt management system according to embodiments of thepresent invention will be described below with reference to thedrawings.

A conveyor belt management system 1 (hereinafter referred to asmanagement system 1) according to an embodiment of the present inventionillustrated in FIG. 1 calculates during use period a remaining servicelife Ja of a conveyor belt 12 installed on a belt conveyor device 9 at ause site illustrated in FIGS. 6 and 7.

In the belt conveyor device 9, the conveyor belt 12 is mounted around adrive pulley 10 a and a driven pulley 10 b at a predetermined tension.Between the drive pulley 10 a and the driven pulley 10 b, the conveyorbelt 12 is supported by support rollers 10 c disposed at appropriateintervals in the belt longitudinal direction.

The conveyor belt 12 is constituted by a core layer 14 including a core15 made of a steel cord or canvas, and an upper cover rubber 13 a and alower cover rubber 13 b that sandwich the core layer 14 therebetween.The core layer 14 is a member bearing the tension caused when theconveyor belt 12 is mounted at tension. The conveyor belt 12 may includeadditional necessary members, such as a width direction end portionrubber 13 c or a reinforcing layer, as appropriate.

The lower cover rubber 13 b is supported by the support rollers 10 c ona carrying side of the conveyor belt 12, and the upper cover rubber 13 ais supported by the support rollers 10 c on a return side of theconveyor belt 12. Three of the support rollers 10 c are arranged on thecarrying side of the conveyor belt 12 side by side in the belt widthdirection. The conveyor belt 12 is supported by these support rollers 10c in a recessed shape having a prescribed trough angle.

The drive pulley 10 a is rotationally driven by a drive motor. A take-upmechanism 11 moves the driven pulley 10 b to apply a desired tension tothe conveyor belt 12 (core layer 14) by changing the interval betweenthe drive pulley 10 a and the driven pulley 10 b.

The conveyor belt 12 may be formed from a plurality of conveyor belts ofany length by splicing together the longitudinal end portions of thecore layers 14 of the conveyor belts to form an annular shape. In thecase of a conveyor belt 12 having a short circumferential length, thelongitudinal end portions of the core layer 14 of one conveyor belt 12may be spliced together to form an annular shape. Thus, as illustratedin FIG. 8, the conveyor belt 12 includes a portion where the core layer14 is spliced together in the longitudinal direction (an endless portion16B) and a non-endless portion 16A disposed adjacent to one another inthe longitudinal direction. In the conveyor belt 12, the core layer 14is formed from a plurality of steel cords 15 arranged side by side inthe belt width direction. In the endless portion 16B, every second steelcord 15 extending from each of the non-endless portions 16A on oppositesides in the belt longitudinal direction is inserted between the steelcords 15 on the other side in the belt width direction.

In a case in which the core layer 14 is made of canvas, in the endlessportion 16B, the canvas extending from each of the non-endless portions16A on opposite sides in the belt longitudinal direction may have aknown structure such as being joined in a step shape. In the non-endlessportion 16A, the core layer 14 is continuous without a joint, but in theendless portion 16B, the core layer 14 has such a joint. Thus, theendless portion 16B and the non-endless portion 16A show differences inelongation, tensile strength, and flexibility (bending rigidity).

Conveyed objects C conveyed by another conveyor belt are fed onto theupper cover rubber 13 a of the conveyor belt 12 and conveyed to aconveying destination by the conveyor belt 12. The conveyed objects Cmay be fed onto the conveyor belt 12 via a hopper or the like.

The upper cover rubber 13 a is subjected to impact from the fed conveyedobjects C. Additionally, on the upper cover rubber 13 a, the conveyedobjects C immediately after being fed and placed press against the uppercover rubber 13 a with a predetermined surface pressure and move in adirection opposite to the running direction of the conveyor belt 12. Atthis time, friction force acts on the upper cover rubber 13 a. The uppercover rubber 13 a is worn primarily by this behavior of the conveyedobjects C. The width direction end portion rubber 13 c may slide andwear against a guide or the like of the belt conveyor device 9. Thelower cover rubber 13 b may slide and wear against the support rollers10 c that cannot rotate or not rotate smoothly. The lower cover rubber13 b may wear due to slippage between the lower cover rubber 13 b andthe pulleys 10 a, 10 b due to insufficient tension acting on theconveyor belt 12 or the like. The lower cover rubber 13 b may slide andwear against a scraper provided to remove the conveyed objects C thathave dropped onto the lower cover rubber 13 b.

The management system 1 includes an input unit 5 (5 a to 5 g) and aserver 2 into which data is input by the input unit 5. The server 2includes a calculation unit 3 (microprocessor) and a storage unit 4(memory).

The input unit 5 and the server 2 are communicably connected. In thisembodiment, the management system 1 includes seven types of input units5 a to 5 g, and the input units 5 are connected to a transmission unit6. The data input by the input unit 5 is transmitted from thetransmission unit 6 to the server 2. In addition, the server 2 iscommunicably connected to a customer terminal device 7 and amanufacturer terminal device 8. For example, a personal computer or thelike is used for the customer terminal device 7 and the manufacturerterminal device 8. The server 2, the input unit 5, the customer terminaldevice 7, and the manufacturer terminal device 8 can each be connectedthrough, for example, an Internet network.

The server 2 is installed, for example, in the company of thedistributor that distributes the conveyor belt 12. The input unit 5 isdisposed, for example, at the use site of the conveyor belt 12. Thecustomer terminal device 7 is installed, for example, in the company ofthe user of the conveyor belt 12. The manufacturer terminal device 8 isinstalled, for example, in the company (factory) of the manufacturer ofthe conveyor belt 12. When the distributor and the manufacturer of theconveyor belt 12 are the same (manufacturer/distributor of the conveyorbelt 12), for example, the server 2 and the manufacturer terminal device8 are disposed in the company of the manufacturer/distributor.

The frequency at which data is input to the server 2 by the input units5 may be irregular, with an appropriate number of times during one weekor one month, but the frequency is preferably regular with a certaintime period. The frequency of input may be, for example, once per day,once per week, once per month, or the like.

The wear amount input unit 5 a has as an input item an amount of wear P1of the rubber including at least the upper cover rubber 13 a of theconveyor belt 12. The input item of the wear amount input unit 5 a mayonly include the amount of wear of the upper cover rubber 13 a. However,for example, the amount of wear of the lower cover rubber 13 b and/orthe width direction end portion rubber 13 c may also be included as aninput item. For the wear amount input unit 5 a, various types of wearamount sensors can be employed for detecting the amount of wear of theupper cover rubber 13 a. Alternatively, an input terminal device (suchas a personal computer) into which a worker inputs the amount of wear P1data into the server 2 can be used as the wear amount input unit 5 a.

The input item of the impact force input unit 5 b is an impact force P2that acts on the conveyor belt 12, the input item of the tensile forceinput unit 5 c is a tensile force P3 that acts on the conveyor belt 12,the input item of the core state input unit 5 d is an indicator P4indicating the state of the core 15, the input item of the endlessportion state input unit 5 e is an indicator P5 indicating the state ofthe endless portion 16B, the input item of the device state input unit 5f is an indicator P6 indicating the state of the belt conveyor device 9,and the input item of the use environment input unit 5 g is an indicatorP7 indicating the use environment of the conveyor belt 12.

In an embodiment of the present invention, in addition to the wearamount input unit 5 a with the amount of wear P1 as an input item, theinput unit 5 is only required to have at least one of the six inputitems (P2 to P7) described above as input items. Thus, in the use periodof the conveyor belt 12, a configuration may be employed in which, inaddition to the amount of wear P1, one, two, three, four, or five inputitems selected from the six input items (P2 to P7) are input by theinput unit 5. Alternatively, in addition to the amount of wear P1, aconfiguration may be employed in which the six input items (P2 to P7)are input by the input unit 5, such as in this embodiment.

For the impact force input unit 5 b, various types of impact forcesensors can be employed for detecting the impact force P2 acting on theconveyor belt 12 (upper cover rubber 13 a). Alternatively, an inputterminal device (such as a personal computer) into which a worker inputsthe impact force P2 data into the server 2 can be used as the impactforce input unit 5 b.

For the tensile force input unit 5 c, various types of tensile forcesensors can be employed for detecting the tensile force P3 acting on theconveyor belt 12 (core layer 14). Alternatively, an input terminaldevice (such as a personal computer) into which a worker inputs thetensile force P3 data into the server 2 can be used as the tensile forceinput unit 5 c.

An example of the indicator P4 indicating the state of the core 15includes the gap between the cores 15 arranged side by side in the beltwidth direction. For example, an X-ray device that detects the gap inthe width direction by X-ray radiation may be used for the core stateinput unit 5 d. Alternatively, an input terminal device (such as apersonal computer) into which a worker inputs the indicator P4 data intothe server 2 can be used as the core state input unit 5 d.

An example of the indicator P5 indicating the state of the endlessportion 16B includes a bonding length of the endless portion 16B. Forthe endless portion state input unit 5 e, for example, a length sensorthat detects the interval between marks (colored rubber, engravings, orthe like) embedded at both positions at the longitudinal ends of theendless portion 16B, and the like may be employed. Alternatively, aninput terminal device (such as a personal computer) into which a workerinputs the indicator P5 data into the server 2 can be used as theendless portion state input unit 5 e.

Examples of the indicator P6 indicating the state of the belt conveyordevice 9 include the conveyance speed of the conveyed objects C, theconveyance weight per unit time, the outer diameter of the pulleys 10 a,10 b and the support rollers 10 c, and the like. For the device stateinput unit 5 f, for example, a speed sensor for detecting the conveyancespeed of the conveyed objects C, a weight sensor for detecting theconveyance weight per unit time, and the like may be employed.Alternatively, an input terminal device (such as a personal computer)into which a worker inputs the indicator P6 data into the server 2 canbe used as the device state input unit 5 f.

Examples of the indicator P7 indicating the use environment of theconveyor belt 12 include the use environment temperature and humidity,values identifying specifications of the conveyed objects C (material(hardness, oil content), shape, temperature, and the like), and thelike. For the use environment input unit 5 g, for example, a temperaturesensor, a humidity sensor, a hardness sensor, a digital camera thatrecognizes the shape of the conveyed objects C, and the like can beemployed. Alternatively, an input terminal device (such as a personalcomputer) into which a worker inputs the indicator P7 data into theserver 2 can be used as the use environment input unit 5 g.

The storage unit 4 stores a belt specification database 4 a in which thespecifications of the conveyor belt 12 are input in advance, a tolerancerange database 4 b in which the tolerance ranges for each of the inputitems (P1 to P7) are input in advance per specification of the conveyorbelt 12, and a use condition database 4 c.

In this embodiment, an inventory database 4 d and a correlation database4 e are stored in the storage unit 4. An inventory amount (inventorylength) of replacement conveyor belts 12 a for the conveyor belt 12 atthe use site of the conveyor belt 12 or at a stockyard near the use siteof the conveyor belt is input into the inventory database 4 d. Note thatthe currently used conveyor belt 12 and the replacement conveyor belt 12a may have the same specifications but may also have differentspecifications. For example, the currently used conveyor belt 12 and thereplacement conveyor belt 12 a may differ in the material of the uppercover rubber 13 a.

There is a correlation between the use conditions of the conveyor beltand the specifications of the conveyor belt and the actual service lifeJr of the conveyor belt. Data indicating the correlation between the usecondition and conveyor belt specifications of the multiple conveyorbelts used up until the present and an actual service life Jr of theconveyor belt is input into the correlation database 4 e stored in thestorage unit 4.

As illustrated in FIG. 2, the material, size, and the like of theconstituent members per conveyor belt specification (specification A, B,C, . . . ) are input into the belt specification database 4 a. Forexample, rubber types (rubber physical properties) and layer thicknessesof the upper cover rubber 13 a and the lower cover rubber 13 b, thematerial (physical properties) and the outer diameter of the core 15,the number of cores 15 constituting the core layer 14, the gap in thewidth direction between the cores 15 arranged side by side, the bondinglength of the endless portion 16B, and the like are input.

As illustrated in FIG. 3, the tolerance range for each input item (P1 toP7) per specification (specification A, B, C, . . . ) of the conveyorbelt 12 are input into the tolerance range database 4 b. In thisembodiment, seven input items (P1 to P7) are input into the server 2,with the tolerance ranges of the seven input items. However, in anembodiment in which three input items are input into the server 2, it isonly required that the tolerance ranges of these three input items areinput into the tolerance range database 4 b.

Over time, excessively high levels of the amount of wear P1 of the uppercover rubber 13 a may cause failure. Thus, for example, a tolerancerange with a predetermined upper limit is set for the amount of wear P1.

Excessively high levels of the impact force P2 may cause failure. Thus,for example, a tolerance range with a predetermined upper limit is setfor the impact force P2.

Excessively high levels of the tensile force P3 may cause failure.Excessively low levels may cause failure due to wandering. Thus, forexample, a tolerance range with a predetermined upper limit and lowerlimit is set for the tensile force P3.

Over time, excessively high levels and low levels of the gap in thewidth direction between the cores 15, which is an example of theindicator P4, may cause failure. Thus, for example, a tolerance rangewith a predetermined upper limit and lower limit is set for the gap inthe width direction P4.

Over time, excessively high levels of the bonding length of the endlessportion 16B, which is an example of the indicator P5, may cause peelingat the bond. Thus, for example, a tolerance range with a predeterminedupper limit is set for the bonding length P5.

Excessively high levels of the conveyance speed P6 ₁, which is anexample of the indicator P6, may cause the amount of wear P1 of theupper cover rubber 13 a to increase. Excessively low levels may causethe load weight of the conveyed objects C per unit area to increase,increasing the load on the conveyor belt 12. Thus, for example, atolerance range with a predetermined upper limit and lower limit is setfor the conveyance speed P6 ₁. Excessively high levels of the conveyanceweight P6 ₂ per unit time, which is an example of the indicator P6, maycause the load on the conveyor belt 12 to increase. Thus, for example, atolerance range with a predetermined upper limit is set for theconveyance weight P6 ₂ per unit time.

Excessively high levels and low levels of the typical use environmenttemperature P7 ₁ and humidity P7 ₂, which are examples of the indicatorsP7, may cause failure of the conveyor belt 12. Thus, for example, atolerance range with a predetermined upper limit and lower limit is setfor the temperature P7 ₁ and the humidity P7 ₂. Excessively high levelsof the hardness P7 ₃ of the conveyed objects C, which is another exampleof the indicator P7, may cause damage to the upper cover rubber 13 a.Thus, for example, a tolerance range with a predetermined upper limit isset for the hardness P7 ₃. When the shape P7 ₄ of the conveyed objectsC, which is another example of the indicator P7, includes a portion withan acute angle on the outer surface, the upper cover rubber 13 a may bedamaged. Thus, for example, a tolerance range with a predetermined upperlimit for the proportion of fed conveyed objects C including a portionwith an acute angle on the surface of the conveyed objects C is set forthe shape P7 ₄ of the conveyed objects C.

As illustrated in FIG. 4, the use condition for the belt conveyor device9 at the use site has been input into the use condition database 4 c.Examples of the use condition include the conveyance speed of theconveyed objects C, the conveyance weight per unit time, the outerdiameter of the pulleys 10 a, 10 b and the support rollers 10 c, and thelike. Other examples of the use condition include the use environmenttemperature and humidity of the conveyor belt 12, specifications of theconveyed objects C (material (hardness, oil content), shape,temperature, and the like), and the like.

In other words, the use condition overlaps with the input items P6, P7described above. Thus, the device state input unit 5 f and the useenvironment input unit 5 g can be used to input the use condition datainto the server 2. The use condition is newly updated each time the usecondition change, such as when the type of the conveyed objects Cchanges.

As illustrated in FIG. 5, the inventory amount (inventory length) perconveyor belt specification (specification A, B, C, . . . ) is inputinto the inventory database 4 d. The inventory database 4 d is updatedeach time a replacement conveyor belt 12 a comes in or goes out. Thus,it corresponds to the state of the most current input of the inventoryamount.

The calculation unit 3 is configured to calculate the remaining servicelife Ja of the conveyor belt 12 on the basis of the input item (P1 toP7) data input by the input unit 5, the specifications of the conveyorbelt 12 input into the belt specification database 4 a, and thetolerance ranges of the input items (P1 to P7) input into the tolerancerange database 4 b.

Specifically, the data of each input item input into the server 2 andthe corresponding tolerance range are compared over time. Here, thechange in the amount of wear P1 and the bonding length P5 of the endlessportion 16B has a greater impact on the remaining service life Ja thanthe other input items. Thus, for example, the variation (rate ofvariation) of the input item P1, P5 data relative to the tolerance rangeis calculated. Based on the calculated variation, the time required forthe input data to be outside of the tolerance range is calculated, andthe calculated times are taken as temporary remaining service lives Jb₁,Jb₂. Then, the shortest one of the temporary remaining service livesJb₁, Jb₂ is taken as the remaining service life Ja.

For other input items (P2 to P4, P6, P7), for example, if the data inputinto server 2 is within the tolerance range, the remaining service lifeJa is calculated without taking these data into account. However, ifthese data are outside of the tolerance range, the remaining servicelife Ja is calculated using these data as described below.

In the case of these input item (P2 to P4, P6, P7) data being outside ofthe tolerance range, the load on the conveyor belt 12 may be consideredgreater than in the case of the data being within the tolerance range.Thus, for each of these input items, a coefficient K (0<K<1) that causesthe remaining service life Ja is set to be calculated short. Themagnitude of the coefficient K is not uniform, and may be varieddepending on the input item by weighting the importance of each inputitem based on the previously accumulated performance data.

First, the temporary remaining service life Jb is calculated asdescribed above without using the input item (P2 to P4, P6, P7) data.Next, in a case in which these data are outside of the tolerance range,the coefficients K (K1, K2, K3, . . . ) set for each input item and thecalculated temporary remaining service life Jb are multiplied togetherto calculate the remaining service life Ja (Ja=Jb×K1×K2 . . . ).

In an embodiment of the present invention, the actual service life Jr ofthe conveyor belt 12 is identified based on the calculated remainingservice life Ja. In other words, the conveyor belt 12 use start timepoint and the time point when the remaining service life Ja of theconveyor belt 12 was calculated are known. Thus, the time period fromthe use start time point to the time point when the remaining servicelife Ja was calculated is found. The calculated remaining service lifeJa is added to this found time period to identify the actual servicelife Jr. The actual service life Jr in an embodiment of the presentinvention in principle means a service life identified in this way basedon the calculated remaining service life Ja.

The calculation unit 3 calculates the remaining service life Ja at apredetermined period (e.g., two weeks or one month). In this embodiment,an email notifying of the calculated remaining service life Ja is sentfrom the server 2 to the customer terminal device 7.

In the management system 1 according to an embodiment of the presentinvention, because at least one input item of the other input items P2to P7 is used in addition to the amount of wear P1 of the upper coverrubber 13 a as a basis for calculating the remaining service life Ja, itis possible to calculate the remaining service life Ja in conformancewith the actual status of the use site of the conveyor belt 12 betterthan the related art. In other words, the remaining service life Ja canbe determined with higher accuracy, making it easier to determine asuitable replacement period for the conveyor belt 12. This isadvantageous in reducing the running costs of the conveyor belt 12.

In this embodiment, a communication is transmitted from the server 2 tothe customer terminal device 7 notifying of an order period for thereplacement conveyor belt 12 a or a prompt to order the replacementconveyor belt 12 a based on the amount of the conveyor belt 12 ininventory input into the inventory database 4 d and the calculatedremaining service life Ja of the conveyor belt 12.

Specifically, each time the calculation unit 3 calculates the remainingservice life Ja, the amount of the conveyor belt 12 in inventory inputinto the inventory database 4 d at the current time point is confirmed.If the required length of the replacement conveyor belt 12 a is longerthan the confirmed amount in inventory, the amount in inventory isinsufficient. In this case, an email notifying of an order period of thereplacement conveyor belt 12 a identified by referencing the calculatedremaining service life Ja and a predetermined period of time needed fordelivery is sent from the server 2 to the customer terminal device 7.When the order period approaches, an email prompting the order of thereplacement conveyor belt 12 a is sent from the server 2 to the customerterminal device 7. As a result, sufficient preparation can be done forthe replacing the conveyor belt 12.

When there is communication of an order for the replacement conveyorbelt 12 a from the customer terminal device 7, the communication istransmitted to the manufacturer terminal device 8 via the server 2 ordirectly to the manufacturer terminal device 8. Based on this order, themanufacturer delivers the conveyor belt 12 a of the orderedspecifications and length to the stockyard of the customer.

Note that for conveyor belts 12 with a short circumferential length, all(the entire circumferential length) of the conveyor belt 12 can bereplaced, and for conveyor belts 12 with a long circumferential length,only the necessary portions (required length) can be replaced. Thus, forexample, for input items (P1, P4 and P5), input data and data foridentifying the position on the conveyor belt 12 in the circumferentialdirection corresponding to this data are both input into the server 2.In this way, the position and length of the conveyor belt 12 in need ofreplacement can be determined.

In this embodiment, an expected service life Jf of the conveyor belt 12is calculated by the calculation unit 3 before the conveyor belt 12 isinstalled on the belt conveyor device 9, on the basis of the useconditions of the conveyor belt 12 on the belt conveyor device 9 at theuse site, the specifications of the conveyor belt 12, and thecorrelation described above determined in advance.

Specifically, by analyzing the data of the use condition (the inputitems P6, P7 described above), the belt specifications, and the actualservice life collected of the conveyor belt 12 used up until thepresent, the correlation between the use condition and the beltspecifications and the actual service life are determined. Thus, thedata of the use condition (the input items P6, P7 described above) ofthe conveyor belt 12, the data of the specifications of the conveyorbelt 12, and the correlation database 4 e are used to calculate theexpected service life Jf of the conveyor belt 12. The calculatedexpected service life Jf is transmitted from the server 2 to thecustomer terminal device 7.

The calculated expected service life Jf has a slight error margin. Thus,the remaining service life Ja is calculated as described above, makingit easier to determine a more suitable replacement period for theconveyor belt 12.

Here, the data of the use condition, the belt specifications, and theactual service life Jr of the used conveyor belt 12 are input, stored,and updated in the correlation database 4 e. When calculating theexpected service life Jf of the replacement conveyor belt 12 to be used,an updated correlation database 4 e is used.

Specifically, the expected service life Jf of each of the replacementconveyor belts 12 a to be used is calculated by the calculation unit 3before the conveyor belt 12 a is installed on the belt conveyor device 9based on the use condition and the belt specifications using thecorrelation database 4 e updated each time the conveyor belt 12 (12 a)is replaced. By updating the correlation database 4 e in this way, theseverity of the most recent use condition can be reflected. As a result,the expected accuracy of the expected service life Jf of the conveyorbelt 12 (12 a) is improved.

A database in which the cost required to replace the conveyor belt 12 isinput, a database in which the time required for replacement is input,and the like can be stored in the storage unit 4 of the server 2. Insuch a configuration, the cost information required to replace theconveyor belt 12 can be transmitted from the server 2 to the customerterminal device 7. In addition, schedule management required forreplacement of the conveyor belt 12 can be performed in a centralizedmanner using the server 2.

In a case in which the amount of wear P1 of the lower cover rubber 13 bis added as an input item, the tolerance range (upper limit value) forthe amount of wear P1 is input in advance into the tolerance rangedatabase 4 b. Furthermore, in a case in which the amount of wear P1 ofthe lower cover rubber 13 b input into the server 2 is outside of thetolerance range, an email may be sent to the customer terminal device 7and/or the manufacturer terminal device 8 notifying that the amount ofwear P1 is outside of the tolerance range. The customer or manufacturerthat receives this email performs an inspection such as checking therotation state of the support rollers 10 c of the belt conveyor device9, checking whether slippage is occurring between the conveyor belt 12and the pulleys 10 a, 10 b, and checking whether the scraper is cominginto contact with the lower cover rubber 13 b. As a result, defects inthe belt conveyor device 9 can be eliminated in the early stages.

REFERENCE SIGNS LIST

-   1 Management system-   2 Server-   3 Calculation unit-   4 Storage unit-   4 a Belt specification database-   4 b Tolerance range database-   4 c Use condition database-   4 d Inventory database-   4 e Correlation database-   5 Input unit-   5 a Wear amount input unit-   5 b Impact force input unit-   5 c Tensile force input unit-   5 d Core state input unit-   5 e Endless portion state input unit-   5 f Device state input unit-   5 g Use environment input unit-   6 Transmission unit-   7 Customer terminal device-   8 Manufacturer terminal device-   9 Belt conveyor device-   10 a Drive pulley-   10 b Driven pulley-   10 c Support roller-   11 Take-up mechanism-   12 Conveyor belt-   13 a Upper cover rubber-   13 b Lower cover rubber-   13 c Width direction end portion rubber-   14 Core layer-   15 Core (steel cord)-   16A Non-endless portion-   16B Endless portion-   C Conveyed object

1. A conveyor belt management system, comprising: an input unit with anamount of wear of a rubber comprising at least an upper cover rubber ofa conveyor belt installed at a use site as an input item; an input unitwith at least one input item from six input items consisting of animpact force acting on the conveyor belt, a tensile force, an indicatorindicating a state of a core, an indicator indicating a state of anendless portion, an indicating a state of a belt conveyor device onwhich the belt conveyor is installed, and an indicator indicating a useenvironment of the conveyor belt as an input item; and a server intowhich data of each of the input items are input; the server comprising acalculation unit and a storage unit, the storage unit being configuredto store a belt specification database in which specifications of theconveyor belt are input in advance and a tolerance range database inwhich a tolerance range for each of the input items input into theserver per each of the specifications of the conveyor belt is input inadvance, and the calculation unit being configured to calculate aremaining service life of the conveyor belt based on the data of theinput items input into the server, the specifications of the conveyorbelt input into the belt specification database, and the tolerance rangeinput into the tolerance range database.
 2. The conveyor belt managementsystem according to claim 1, wherein an inventory database into which aninventory amount of replacement conveyor belts for the conveyor belt atthe use site or at a stockyard near the use site of the conveyor belt isinput is stored in the storage unit; the server is communicablyconnected to a customer terminal device; and communication notifying ofan order period of the replacement conveyor belt or communicationprompting order thereof is send from the server to the customer terminaldevice based on the inventory amount input in the inventory database andthe remaining service life calculated.
 3. The conveyor belt managementsystem according to claim 1, wherein an expected service life of theconveyor belt is calculated by the calculation unit before the conveyorbelt is installed on the belt conveyor device based on the use conditionof the belt conveyor device at the use site, the specifications of theconveyor belt input into the belt specification database, and thecorrelation between the use condition of the conveyor belt and thespecifications of the conveyor belt and an actual service life of theconveyor belt determined beforehand.
 4. The conveyor belt managementsystem according to claim 3, wherein in calculating the expected servicelife of a conveyor belt used after the conveyor belt, use conditionswhen the conveyor belt is used, specification of the conveyor belt, andthe correlation updated with input of data of the actual service life ofthe conveyor belt are used.
 5. The conveyor belt management systemaccording to claim 2, wherein an expected service life of the conveyorbelt is calculated by the calculation unit before the conveyor belt isinstalled on the belt conveyor device based on the use condition of thebelt conveyor device at the use site, the specifications of the conveyorbelt input into the belt specification database, and the correlationbetween the use condition of the conveyor belt and the specifications ofthe conveyor belt and an actual service life of the conveyor beltdetermined beforehand.
 6. The conveyor belt management system accordingto claim 5, wherein in calculating the expected service life of aconveyor belt used after the conveyor belt, use conditions when theconveyor belt is used, specification of the conveyor belt, and thecorrelation updated with input of data of the actual service life of theconveyor belt are used.